Daniel Burrows
Differential Gauge
Stratford High School
Year 13 Metal Technology,
full-year project
Teacher: Arnold Cox
Daniel's client was the locally based Team Mugen Racing (NZ), one of New Zealand's most successful teams with drivers and mechanics operating two hi-tech 1/10th Nitro Radio Controlled Touring Cars. The cars are powered by 1.6hp racing engines producing over 40,000rpm and reaching speeds of up to 100kph.
Daniel was asked by the team to produce a dial gauge to help the team to accurately measure the strength of the differentials of their radio controlled cars when making set-up changes and building new differentials. The finished tool had to be not only robust and reliable but light enough to be easily handled. In addition they specified that it had to be fully ball-raced and have two attachments - one to fit directly onto the end of the differential when a new one was being built and one which could be attached to the wheel itself to detect when the differential needed changing. These attachments had to be able to be easily removed from the main shaft. And the finished gauge had to provide accurate consistent readings and be easily disassembled to allow for speedy repair if required.
Daniels initial research established that not many products with similar specifications were already on the market.
"The design process itself turned out to be quite difficult because I couldn't find much information on how other similar gauges worked. Creating my own design from scratch meant that I had to solve many problems which took quite a bit of time."
Three initial concepts were developed and discussed with the client and agreement reached on the one which would be best developed for manufacture. Initial costings established that the likely final cost of the product would fit with the target budget. Using mock-ups and modelling the final design was confirmed and potential difficulties in the construction phase identified for further research and experimentation.
The final production phase was carefully planned and final working and operational drawings produced. A number of changes had to be made during manufacture including redesigning the shaft to make the gauge lighter, cleaner looking and easier to construct.
The final product came out under budget and meeting all of the initial requirements of the client.
Comments from client Craig, Team Muger Racing (NZ)
"I think the design Daniel created is straight-out stunning. It does everything we wanted it to and more. I love the professional look and also the overall user friendliness of the gauge. We've used the gauge already and it functioned like a dream - we couldn't believe how consistent the readings were."
